bm 2610007877 04-10

12.

Assembly

To avoid possible injury,disconnect plug from power

source before performing any assembly,adjustments or repairs.

figure 1

Attaching the Bevel lock lever – This miter saw ispackaged with the saw head locked at 0° bevelangle. The bevel lock lever must be attached beforeoperating the tool.

1. Slide the 10 mm flat washer over the shaft (areawith flats).

2. Slide the bevel lock lever over the shaft, aligningthe flats on the shaft to the flats on the lever’smounting hole. The lever should be horizontal withthe handle to the front (see Figure 1).

3. Slide the 6 mm flat washer over the shaft (areawith screw threads) and against the recessed wallof the lever.

4. Finger-tighten the 10mm lock nut on the shaft. Usethe 10mm socket tool to tighten the lock nut. NOTE: The 6/4mm hex key is placed through theholes in the socket tool to assist in tightening.

5. Lift the bevel lock lever and push back down tocheck that the lever is securely in place.

Attaching the Miter lock Knob – Locate the miterlock knob from among the loose parts.

1. Look under the turntable’s front arm above the locklever and locate the 10mm hole (see Figure 1).

2. Insert the long shaft of the miter lock knob throughthis hole until it stops.

3. Turn the knob clockwise (about 10 full revolutions)until it is tight or “locked.”

4. Loosen the knob 1/2 turn to unlock it. The table isnow free to be moved on the base.

Using the Miter lock Knob –

1. Loosen the miter lock knob.

2. While holding the knob in your palm, reach downwith your index or middle finger and pull up thedetent lever. While gripping knob, rotate table leftor right to needed miter angle and release thelever.

3. Tighten the knob once you are at the correct angle.

NOTE: It is recommended to tighten the miter lockknob before all cuts. It is required to tighten the knobbefore cutting at any angle between detentengagements or when the miter detent overridesystem is in use.

Storing the 6/4mm Hex Key – There is a storagelocation on the saw to store the 6/4mm hex key.Insert the short leg of the hex key through the rubbergrommet as shown. Place the long leg into the tool restand press down into the retainer clip (see Figure 2).

NOTE: The 6/4mm hex key is needed to change theblade and to make tool adjustments. If lost, twoseparate hex keys may be substituted: a 4mm hexkey and a 6mm hex key.

figure 2. Hex Key Storage

MiterLock Knob

Bevel LockLever

MiterDetent Lever

Hex Key10mm Socket Tool

Lock Nut

Shaft10 mmWasher

6 mmWasher

WARNING!

Grommet

Tool Rest 6/4mm Hex Key

Retainer Clip

Attaching loose parts

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13.

Assembly



Moving Guard Assembly1. Position the saw in the UP position and at 0°

bevel. If in the DOWN position, press downslightly on the saw head assembly and pull outthe head assembly lock pin (item 43, page 9); thenallow the saw head to come up (see Figure 3).

2. Unscrew the link knob (item 28, page 9) by handfrom the pivot post and allow the link assembly tohang. The link knob will stay on the link.

3. Loosen front cover plate screw two turns using the6/4mm hex key. Do not remove screw. A 4mm hexkey may be used as an alternate.

4. Loosen rear plate screw six full turns using the6/4mm hex key. Do not remove screw.

5. Slide the cover plate down and out from the rearscrew. Rotate the cover plate and lower guardcounterclockwise around the front screw. Whileholding the lower guard up against the upperguard, move the link so its round hole can go overthe rear screw – let go and the lower guard assem -bly will be held out of the way (see Figure 4).

figure 3

figure 4

Removing Blade1. Press and hold the arbor lock (red button on

opposite side of upper guard – item 42, page 9).Rotate the blade slowly while pressing the arborlock until it fully seats into its lock position.

2. Using the 6/4mm hex key, loosen the blade bolt byfirmly turning it clockwise. NOTE: This bolt hasleft-hand threads.

3. Remove the blade bolt and outer washer. Carefullygrab the blade. Slide the blade away from the innerwasher and off the arbor shaft, then down andaway from the saw. Leave the inner washer on thearbor shaft (see Figure 5).

Guard Link

Rear Cover Plate Screw

Cover Plate

Blade Bolt

Blade RotationArrow

Front Cover Plate Screw

Knob

Rear Cover Plate Screw

Link

Cover Plate

WARNING!

Removing and Installing Blades

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14.

Assembly



Installing 12" Blade

To avoid injury, do not use ablade larger or smaller than 12"

diameter and 1" arbor. The blade’s maximumplate thickness is 0.100".

To reduce risk of injury, use sawblade rated 3800/min (RPM) or

greater.

1. Follow all “Moving Guard Assembly” and “Remov-ing Blade” steps.

2. Carefully handle the new blade. Check that therotation arrow on the blade matches the rotationarrow on the lower guard. Slide the blade up andbetween the sides of the chip deflector and overthe arbor shaft. Move the blade so its arbor holegoes around the support ring of the inner washer(see Figures 4 and 5).

3. Place the outer washer over the arbor shaft andfinger-tighten the blade bolt (counterclockwise).Check that the blade remained on the innerwasher’s support ring.

4. Rotate the blade slowly while pressing the arborlock until it fully seats into its lock position.

5. Using the 6/4mm hex key, firmly tighten the bladebolt counterclockwise. NOTE: This bolt has left-hand threads. Do not over tighten. A 6mm hex keymay be used as an alternate.

6. Remove the lower guard link from the rear coverplate screw. Rotate the lower guard and coverplate around the front cover plate screw until thecover plate’s slot slides under the rear cover platescrew head. Fully tighten both cover plate screwsusing the 6/4mm hex key.

7. Place the lower guard link back to the original po-sition, then firmly finger-tighten the link knob to thepivot post. It may be necessary to retract the lowerguard while tightening the link knob.

8. Be sure the arbor lock is released so the bladeturns freely.

9. Place the 6/4mm hex key back in storage area.

Tighten the cover plate screws. loose cover plate screws may

interfere with and hang up lower blade guard.Never use saw without cover plate securely inplace. lower guard will not function properly.

After installing a new blade, make sure the blade does not

interfere with the table insert at 0° and 45° bevelpositions. lower the blade into the blade slot andcheck for any contact with the base or turntablestructure. If the blade contacts base or table,seek authorized service.

figure 5. Blade Hardware

Outer Washer

Inner Washer

Blade Bolt

Saw Blade

Arbor Shaft

Support Ring

WARNING!

WARNING!

WARNING!

WARNING!

Removing and Installing Blades

WARNING!

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15.

Assembly



The dust collection system used on this tool is uniquebecause it is not attached to the upper guard. Thisplacement provides superior dust collection for themajority of cuts. When adjusting or removing any dustcollection components, be sure the saw is unplugged.

Elbow The elbow is attached to the top of the dust chute.NOTE: It is recommended that the elbow is always inplace before operating the tool – it is required to directdust and debris away from the operator. The elbowcan be rotated in place. The elbow supports the dustbag or can be connected to a vacuum cleaner.

Removing Elbow – For cleaning, the elbow may beremoved by pulling up and twisting until it is free ofthe dust chute. Reattach the elbow by pressing andtwisting until it snaps over the chute’s molded-inretaining ring. Always reattach before using the saw.

Attaching and Adjusting the Dust BagAttaching (and Removing) Dust Bag – The elbowhas pins on the top and bottom of the exit port whichwill engage the coupler end of the dust bagassembly. To attach the dust bag, align the coupler’sslots with the elbow’s pins, then push and twist itclockwise. To remove the dust bag, twist the couplercounterclockwise, then pull off – always leave theelbow on the dust chute (see Figure 6).

Adjusting Dust Bag – After attaching the bag, it isrecommended to do a “dry cut” before cutting with thesaw – this means: unplug the tool, preset it forintended cut and practice the cut. For some bevelcuts, the sliding fence may have to be moved orremoved to avoid being cut or making contact withthe dust bag. The bag’s position may also need arotating adjustment if it contacts the workpiece duringa slide cut.

figure 6

Using and Cleaning the Dust BagUsing Dust Bag – Attach the clean bag to the elbow.Adjust the elbow and dust bag, if necessary, so theydo not interfere with the tool during the intendedcutting operation.

Cleaning Dust Bag – After the dust bag is 2/3 to 3/4full, remove it from the saw. Bring the bag to a propercontainer and pull open the zipper located on thebottom of the bag. Hold the bag by the coupler endand shake it vigorously until all the dust and debrisfall from it. Close zipper and reattach the bag.NOTE: Clean the bag at the end of the cuttingsession and before transporting or storing the saw(see Figure 7).

Be extremely careful whendisposing of dust. Materials in

fine particle form may be explosive. Do not throwsawdust on an open fire. Spontaneouscombustion, in time, may result from the mixtureof oil or water with dust particles.

figure 7

Coupler

Zipper

Dust Bag

Dust Chute

Rubber Deflector

Elbow

WARNING!

Coupler Slot PinDust BagElbow

Dust Chute

WARNING!

Assembling Dust Collection System

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16.

Assembly



Attaching a Vacuum CleanerThe elbow has an exit port which will accept astandard 35mm diameter vacuum fitting or a 1-1/4"tube diameter. The 35mm diameter fitting is thestandard size used on the Bosch AirsweepTM VacuumCleaners, Models 3931 and 3931A. For largervacuum tube sizes, use an adaptor.

Attaching to Vacuum – Insert the vacuum fitting ortube into the elbow’s exit port as far as it will go.Check to see that the vacuum hose is free from themechanism and cutting path before plugging saw intopower source.

figure 8. Attaching Vacuum Cleaner

Repositioning or Removing the RubberDeflector

The rubber deflector extends the range of dust anddebris collection and should be left on the tool formaximum dust pickup efficiency. When slide cuttingextra-tall materials (more than 2-13/16" high), therubber deflector will contact and flex over thesematerials. It will also contact and flex when the saw ispulled back before the cut. It will return to its originalshape after the cut.

Repositioning Deflector – If the operator wants toavoid the contact of the rubber deflector with thematerial, the deflector can be temporarily folded upand over the back of the dust chute. If the operatorpermanently wants no contact of the deflector withthe material being cut, the deflector may be removed.

Removing Deflector – Pull one of the deflector’stabs to the front and then sideways until it comes offone of the dust chute’s side hooks (see Figure 9).Unhook the opposite side. Then unhook the deflectorfrom the rear post of the chute by pulling andstretching until it is free. NOTE: Removing thedeflector lowers dust collection capability.

Attaching Deflector – Start by stretching andhooking the deflector over the rear post, followed byhooking over each side hook (see Figure 10).

figure 9. Attaching Rubber Deflector on Rear post

figure 10.Attaching Rubber Deflector on Side Hooks

Side Hook

Rear Post

Side Hook

Rear Post

Rear of Dust Chute

Rubber Deflector

VacuumHoses

35 mmDiameter

1-1/4 inchDiameter

Elbow

ExitPort

Dust Chute

WARNING!

Assembling Dust Collection System

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17.

Adjustments



Head Assembly lock pinThe head assembly lock pin (item 43 - page 9) islocated on the right side of the pivot post (item 34 -page 9). It is used to hold the saw’s head assemblyin the DOWN position. This position prevents thehead from bouncing up and down duringtransportation. This also makes the saw morecompact for lifting and storage. This position is alsorequired for some calibrating procedures.

To Engage the Head Assembly lock pin 1. Check that the depth stop plate (item 33 - page 9)

is disengaged, or pressed in to the left position.

2. Grasp the saw’s main handle (item 3 - page 8) andpress down on the head assembly.

3. While pressing the saw head down, push in on thehead assembly lock pin. Release the headassembly. The head will be locked in the DOWNposition (see Figure 11).

To Disengage the Head Assembly lock pin

1. Grasp the main handle and press down on thehead assembly.

2. While pressing the head down, pull out the headassembly lock pin. Release the lock pin, butmaintain your grip on the main handle. Slowlyallow the spring-loaded saw head to come up tothe top of its travel and then release the handle.

figure 11

WARNING!

Depth StopPlate

Head AssemblyLock Pin

Using the Head Assembly lock pin

To Adjust the Glide Movement Controller

The glide movement controller is attached to theupper joint of the glide mechanism; it is designed tocontrol the smoothness of the saw’s glide action.When assembled at the factory, the controller is notadjusted; therefore, the movement is very smooth. Toadjust the glide mechanism’s smoothness, slightlytighten or loosen the two screws at the top by usingthe 6/4mm hex key or a 4mm hex key (see Figure 12).

figure 12

6/4mm Hex Keyx 2 Screws

Glide MovementController

Using the Glide Movement Controller

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18.

Adjustments



Mechanism lock lever The lock lever (item 27 - page 9) is located on therear left side of the mechanism.

When engaged, it locks the system (item 35 – page9) in either the full forward or the full back positionand prevents movement while transporting the saw.When held in the full back position, the saw is morecompact for lifting and storage. The full back positionis often used while performing chop cuts.

To Engage the lock leverWith Saw in the full Back position –

1. Grasp the saw’s main handle (item 3 - page 8)and push (slide) the head assembly back as far asit goes. The upper housings will be upright andclosed.

2. Lift the tab on the lock lever to engage its wedgeinto the joint area between the two lowerhousings. Release the lock lever tab and the mainhandle. The head assembly will be locked in thefull back position.

figure 13.To Engage in Back position

With Saw in the full forward position –

1. Grasp the main handle (item 3 - page 8) and pull(slide) the head assembly toward you as far as itgoes. The mechanism will be fully extended.

2. Lift the tab on the lock lever to engage its wedgeinto the joint area between the two lowerhousings. Release the lock lever tab and the mainhandle. The head assembly will be locked in thefull forward position.

figure 14

To Release the lock leverfrom Back or forward positions –

1. Grip the tab on the lock lever and press down untilits wedge comes out from between the two lowerhousings. Release your grip; the mechanism isnow free to slide forward and back.

figure 15.To Release in front or Back position

Lock Lever Tab

LockLever Tab

Lock Lever Tab

WARNING!

Using the Mechanism lock lever

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19.

Adjustments



When a new blade is installed, it may be necessaryto check the clearance of the blade to the turntablestructure. The depth stop plate is a feature providedto allow for (normal) full-depth cuts or non-throughcuts used to cut grooves.

Setting Blade Depth for Normal full-Depth Cuts

1. When making normal full-depth cuts, push thedepth stop plate in toward the saw head (seeFigure 16). This will allow the depth stop screw topass through the hole in the plate.

2. Check for full depth of cut:

- Set table at 0° miter and push saw fully back.

- Pull out head assembly lock pin to the releaseposition.

- Push down saw head and watch the depth stopscrew pass through the stop plate without anybinding or contact with the plate.

Setting Blade Depth for Non-ThroughCuts for Cutting Grooves

NOTE: For best results, Bosch recommends the useof a table saw with an optional dado blade set forcutting grooves and non-through cuts. In the eventthis is not available, the feature described below is aconvenient alternative.

1. Release (pull out) the head asembly lock pin andallow the saw head to move fully up. Slide sawhead to the full back position.

2. Pull the depth stop plate out away from the sawhead (see Figure 17).

3. Grip the main handle (item 3, page 8) and pushdown the saw head while watching the depth stopscrew contact the top surface of the depth stopplate. The screw will not pass through the hole inthe plate.

4. Turn the knob at the end of the depth stop screw(while the threaded end is in contact with stopplate) and watch the bottom of the saw blademove. This adjustment sets the depth of cut.

See page 44 for “Cutting Grooves” instructions.

figure 16

figure 17

DepthStop Screw

Depth StopPlate

DepthStop Screw

Depth StopPlate

Head AssemblyLock Pin

WARNING!

Depth of Cut Adjustment

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20.

AdjustmentsMiter Detent System – Adjustment procedure

Calibrating Miter Detent System1. Engage the miter detent at the 0° position. Loosen

the miter lock knob 1/2 turn.

2. Look for four round holes in the miter scale plate.In each hole is a screw. Use the small end of the6/4mm hex key or a 4mm hex key to loosen allfour screws 1 to 2 turns. This will loosen the miterdetent plate (see Figure 18).

figure 18

3. Lock saw down using the head assembly lock pin(item 43 – page 9).

4. Hold one side of a 90° combination square againstthe fence and rotate the table (and detent plate)until the side of the saw blade is in full contact withthe other side of the square.

figure 19

5. Tighten all four screws – loosen and reset themiter scale pointer to the “0” position.

Miter Scale pointer Adjustment1. Rotate table to 0° position and lock in place.

2. Raise the head assembly to the full UP position.

3. Loosen the pointer adjust screw that holds themiter scale pointer in place (see Figure 20).

4. Position the pointer to align with the 0° line.Tighten the screw.

figure 20. Miter Scale Adjustment

Kerf Insert AdjustmentThe kerf inserts should be adjusted close to theblade, but without touching the blade, to avoid tear-out on the bottom of the workpiece.

1. Hold the saw head assembly down and push inthe head assembly lock pin (item 43 – page 9) tokeep the saw in the DOWN position.

2. Loosen the six kerf screws using a #2 Phillipsscrewdriver.

3. Adjust the kerf inserts as close to the blade (teeth)as possible without touching the blade.

4. Tighten the kerf screws.

NOTE: At extreme bevel angles, the saw blade mayslightly cut into kerf insert.

figure 21. Kerf Inserts

Kerf Inserts

Kerf Screws

Pointer Adjust Screw

Miter Scale Pointer 0° Line

Contacting Fence

Contacting Blade

CombinationSquare

Set MiterDetent at 0°

Detent Plate

Screws

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21.

Adjustments


source before performing any assembly,adjustment or repair.

Checking 0° Bevel Stop Setting1. Hold the saw head assembly down and push in

the head assembly lock pin (item 43 – page 9) tokeep the saw in the DOWN position.

2. Slide the head assembly completely to the backand engage the lock lever (item 27 – page 9) bylifting up the finger tab.

3. Rotate the table to the 0° miter position.

4. Pull up the bevel lock lever to loosen.

5. Check the position of the bevel range selectorknob; it should be at the “0-45° Left” position.

6. Tilt the saw assembly to the left(counterclockwise), then rotate to the right(clockwise) until it hits the stop in the verticalposition – this is where the saw is currently set tomake a 0° cut.

7. Push down the bevel lock lever to lock the angleposition.

8. Use a combination square to check that the bladeis 90° (square) to the table. Place the square’sruler edge against the table and slide it to contactthe blade with the vertical side of the square’shead (see Figure 22).

figure 22

9. Check that the saw blade’s plate (not teeth) istouching the square’s 90° side. If the saw blade’splate is not in full contact with the square’s body90° side, follow the “Adjusting 0° Bevel Stop”procedures.

WARNING!

0° Bevel Stop – Adjustment procedure

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22.

Adjustments



Adjusting 0° Bevel Stop (Blade 90° to Table)

1. Pull up the bevel lock lever to loosen.

2. Loosen bolt heads “A” and “B” using a 10mm openend wrench or socket (with socket wrench).Loosen bolts at least one full turn (see Figure 23).

3. Loosen set screw “D” using the 4mm end of the6/4mm hex key (provided with tool, but may alsouse a standard 4mm hex key). Loosen screw atleast three full turns.

4. Place combination square on table and againstblade (see Figure 22).

5. Using the 4mm end of hex key, turn set screw “C”and watch the saw blade tilt. Turn screw “C” untilthe blade is aligned (full contact) with the square’sbody’s edge. After aligning, remove hex key.

6. Tighten set screw “D” using 4mm hex key.

7. Tighten bolt heads “A” and “B” using 10mm openend wrench.

8. Adjust bevel scale pointers (item 36 – page 9) tobe in line with the bevel scale’s 0° lines.

9. Push down the bevel lock lever to lock.

WARNING!


figure 23

Adjusting Bevel Stops

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23.

Adjustments



Checking 45° Bevel Stop Setting1. Hold the saw head assembly down and push in

the head assembly lock pin (item 43 – page 9) tokeep the saw in the DOWN position.

2. Slide the head assembly completely to the backand engage the lock lever (item 27 – page 9) bylifting up the finger tab.

3. Rotate the table to the 0° miter position.

4. Pull up the bevel lock lever to unlock. Move the leftsliding fence fully to the left.

5. Check the position of the bevel range selectorknob; it should be at the “0-45° Left” position.

6. Tilt the saw assembly to the left(counterclockwise) until it hits the 45° stop – this iswhere the saw’s 45° stop is set to make a 45° leftbevel cut.

7. Use a combination square to check that the bladeis 45° to the table. Remove the rule blade from thecombination square. Place only the combinationsquare’s head on the saw’s table with its long flatside resting on the table and its 45° side againstthe tilted blade (see Figure 24).

figure 24

8. Check that only the saw blade’s plate (not teeth) istouching the square’s 45° side. If the saw blade’splate is not in full contact with the square’s head45° side, follow the “Adjusting 45° Bevel Stop”procedures.

Contacting Table

Contacting BladeCombination

Square Head

WARNING!


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24.

Adjustments



Adjusting 45° Bevel Stop (Saw Blade 45° to Table)

1. Pull up the bevel lock lever to unlock. Move the leftsliding fence fully to the left.

2. Tilt the saw assembly to the left(counterclockwise) until it hits the 45° stop.

3. Place only the combination square’s head on thesaw’s table with its long flat side resting on thetable and its 45° side against the tilted blade.

4. Place an 8mm open end wrench on bolt head “F”(see Figure 25).

5. While turning bolt “F,” watch the blade tilt – turn “F”until the saw blade plate is in full contact with the45° side of the square’s head (see Figure 24).

6. If needed, adjust bevel scale pointers (item 36 –page 9) to be in line with the bevel scale’s 45°lines. First, adjust right bevel pointer; then tilt sawhead to the right 45° stop position (see page 41 –“Bevel Range 2 = 0-45° Right”) and adjust the leftbevel pointer. Tilt the saw head to the 0° position– both pointers should be on the bevel scale’s 0°lines.

7. Push down the bevel lock lever to lock at thedesired bevel angle.

WARNING!


figure 25

Adjusting Bevel Stops

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25.

Adjustments

Checking Bevel lock Tension1. Pull up the bevel lock lever to release tension. If it

feels too hard to pull up, an adjustment may berequired.

2. Check the tilt resistance. Grab main handle andslowly tilt the saw to the left. While tilting, someresistance should be felt. At approximately 30°, theresistance should become lower. If little or noresistance is felt, an adjustment may be required.

3. Check bevel lock tension. Push down on the bevellock lever – normally more pressure is needed at thestart; then the lever should go fully down to the lockposition with a “thump”.A) If it is too hard to push the lever fully down, thenit may require tension adjustment.B) Check locking power: Tilt the saw to about 30°and push down on bevel lock lever. Firmly press onthe right side of the saw head - If the saw head tiltsmore than 1/2° from the locked position, then thebevel lock tension needs adjustment.

Adjusting Bevel lock TensionThe bevel lock lever tension has been set at the factory.After extensive use of the tool, it may requireanadjustment. Before adjusting tension, the tilt resistanceshould be set.

1. Pull up the bevel lock lever to release tension.

2. Adjusting Tilt Resistance (see step 2 above).A) If resistance is too low, slightly tighten (1/16thturn) the large lock nut “H” using a 24mm socket orwrench.B) If resistance is too high, slightly loosen (1/16thturn) the large lock nut “H” using a 24mm socket orwrench.

3. Adjusting Tension (see steps 1 and 3 above) Pullup and push down the bevel lock lever. A) If the lever is too hard to pull or push, thetension can be decreased by using a 17mmsocket or wrench to loosen lock nut “E” (1/8thturn). Check again.B) If the lever is too easy to pull or push or if thesaw head does not fully lock at a bevel setting,then the tension can be increased by using a17mm socket or wrench to tighten lock nut “E”(1/8th turn). Check again.

figure 26

Adjusting Bevel lock Tension

The front stabilizing bolt is located on the bottom of thesaw’s base near the 0° miter detent slot (Figure 26a).It provides additional support when making slide cuts.

The stabilizing bolt has been factory set. If it is loose orneeds adjustment, follow these steps:

1. Move the saw so that you have easy access to thebolt area. Loosen the stabilizing bolt and the jam nutusing a 10mm wrench.

2. Place the saw back on your work table. Unscrew thestabilizing nut until it contacts the table.

3. Move the saw again so that you have access to thebolt area. While holding the head of the bolt with a10mm wrench or pliers, use a 10mm open endwrench to fully tighten the jam nut against the bossin the saw’s base.

Boss

Jam NutStabilizing Bolt

Adjusting Front Stabilizing Bolt

figure 26a

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bm 2610007877 04-10

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